Method for assembling layers of packages on a pallet

ABSTRACT

A method and apparatus for arranging bags in layers with the sewn end of each bag in each layer facing inwardly of the layer and for depositing each layer on a pallet. Some bags are turned 180* and some bags are turned 90* while the bags are being conveyed to a marshalling station where the bags are gathered sequentially in groups. The first two groups are sequentially moved onto a plate to form a layer of bags having a predetermined pattern. Then, the plate is moved over a pallet and the layer is wiped off the plate over the pallet while the plate is retracted. The next two groups are arranged in a layer having a different pattern and deposited over the pallet in like manner. These steps are repeated several times to quickly deposit eight layers on the pallet with adjacent layers having interlocking patterns. Preferably, 90* turning of a bag is accomplished by blocking movement of the bag on one side near one end while quickly moving a guide member along the other side of the bag toward the other end and then quickly retracting the guide member.

[4 Oct. 24, 1972 Primary Examiner-Robert J. Spar Attorney.-Greist, Lockwood, Greenawalt & Dewey [57] ABSTRACT A method and apparatus for arranging bags in layers with the sewn end of each bag in each layer facing inwardly of the layer and for depositing each layer on a pallet. Some bags are turned 180 and some bags are turned 90 while the bags are being conveyed to a marshalling station where the bags are gathered sequentially in groups. The first two groups are sequentially moved onto a plate to form a layer of bags having a predetermined pattern. Then, the plate is moved over a pallet and the layer is wiped off the plate over the pallet while the plate is retracted. The next two groups are arranged in a layer having a dif- .ferent pattern and deposited over the pallet in like manner.""-'ljhesesteps are" repeated several times to OF PACKAGES ON A PALLET [72] Inventors: Kenneth G. Kurk; Robert S. Kil- I bride, both of Quincy, lll. [73] Assignee: Moor-man Manufacturing Company,

Quincy, Ill.

Nov. 16, 1970 21 Appl. No.: 89,658

US. Cl. ................2l4/152, 53/187, 198/33 AB, 214/6 DK, 214/6 P .B65g 57/26 Field of Search .............2l4/6 P, 6 H, 6 DK, 6.5; 198/33 AB References Cited UNI'IEDSTA'I'ESPATENTS United States Patent Kurk et al.

[54] METHOD FOR ASSEMBLING LAYERS [22] Filed:

[51 Int.

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SHEET OBUF 11 INVENTORS KENNETH KURK R0 ERT s. K/BR/DE PAIENTED um 24 I972 SHEET 08 0F 11 P'A'TENTED um 24 I972 SHEET USUF 11 INVENTORS KENNETH KURK ROB RT S. K! BR E ajwd ATT Y PA'TENTElJncr 24 m2 SHEET 11 0F 11 as wwwm METHOD FOR ASSEMBLING LAYERS F PACKAGES ON A PALLET The present invention relates to improvements and innovations in a method and apparatus for assembling layers of filled containers or packages on a pallet. More particularly, the present invention relates to a method for quickly and efficiently assembling layers of bags on a pallet with the bags in each layer having a predetermined orientation for interlocking with adjacent layers, and preferably with a specified end of each bag in each layer facing inwardly of the layer, and to an apparatus, hereinafter referred to as an automatic palletizer, for assembling the layers of bags on the pallet with the desired orientation of each bag in each layer.

l-Ieretofore, a variety of devices have been proposed for arranging layers of packages on a pallet with the packages in each layer having a predetermined orientation. Some of these known devices are primarily used for arranging bags into layers, each layer being formed with one group of two packages extending end to end and with another group of three or more packages arranged side. by side, and the patterns of adjacent layers being in opposite hand relation to each other so that each package in one layer contacts two packages in an adjacent layer. In, this way, a frictional interlocking between adjacent layers is obtained. One known device for assembling bags in this manner is disclosed in US. Pat. No. 2,813,638 issued to F. H. Miller Jr. on Nov. 19, 1957.

Palletizing devices of this type are useful in plants, such as an animal feed processing plant, where bags are continuously being filled and closed and then are stacked on pallets for temporary storage. In such plants it is common to use a machine for continuously filling and closing the bags. In one such machine, the bags exit from the machine in upright position on a continuous conveyor, at a rate of approximately 20 bags per minute, and a difficulty encountered with the presently known palletizing devices is the inability of these known devices to handle bags at a rate of approximately 20 bags per minute.

Moreover, another difficulty encountered with the known devices is the inability of these known devices to stack layers of bags on a pallet with a specified. end of each bag extending inwardly of the layer. This is important where the specified end is the closed or sewn end which has a loose thread end serving as a draw string and it is desirable to arrange the bags on the pallet in layers with the sewn end of each bag in each layer facing inwardly of each layer to prevent premature opening of the bag by accidental or intentional pulling of the draw string.

Additionally, another difficulty encountered with the known devices is the inability of these known devices to stack layers of bags on a pallet where the dimensions or extent of the pallet is less than the dimensions or extent of the layers, that is to say, where the outer margin of the bottom layer of bags extends over the edges of the pallet.

In many instances, the size of the bags is such that the longitudinal extent of two bags arranged end to end is less than the lateral extent of a plurality of bags arranged side by side. In these instances, it is desirable that some means be provided for separating the two bags arranged end to end in the layer so that the outer ends of these two bags will be aligned with the outer sides of the respective two bags of the plurality of bags arranged side by side to square the corners of each layer with the comers of the adjacent layers and thereby provide a more stable stack of layers on a pallet.

Still another difficulty encountered with presently known palletizing devices is the inability of these devices to square the corners of layers formed of bags having the above described length to width relationship.

Additionally it is desirable to provide some means for wrapping the layers on the pallet to protect the same from the elements and to further stabilize the stacked pallet and thereby inhibit, if not prevent, toppling of the layers or shifting of the bags in each'layer during subsequent handling of the stacked pallet. In this respect, it is desirable that the palletizing device be capable of being combined with a conventional shrink wrap mechanism so that stacked pallets can be ject of the present invention to provide a method for rapidly and quickly assembling layers of filled containers on a pallet with the filled containers in each layer having a predetermined orientation.

Another object of the present invention is to provide a method for assembling layers of packages on a pallet at a rate of at least twenty packages per minute and with the packages in each layer arranged in a predetermined pattern.

Another object of the present invention is to provide a method for assembling elongated packages having a first end and a second end on a pallet with the packages in each layer having a predetermined orientation and with the first end of each package in each layer facing inwardly of the layer.

Another object of the present invention is to provide a method for assembling layers of packages on a pallet with the packages in each layer arranged in a predetermined pattern, and in which selected packages are turned 180 while the packages are being fed to a marshalling station. 7

Another object of the present invention is to provide a method for assembling layers of elongated packages on a pallet with the containers in each layer arranged in a predetermined pattern and for squaring the corners of each layer where the longitudinal extent of two packages abutting each other end to end in each layer is less than the lateral extent of other packages arranged side by side in the layer.

Another object of the present invention is to provide a method for assembling layers of elongated containers on a pallet with the containers in each layer arranged in a predetermined pattern and in which selected packages are quickly turned while the packages are being fed to a marshalling station.

Another object of the present invention is to provide an apparatus for rapidly assembling layers of packages on a pallet with the packages in each layer each having a predetermined orientation.

Another object of the present invention is to provide an apparatus for assembling layers of bags on a pallet with the bags in each layer each having a predetermined orientation, and with the outer margins of the layers overlapping the edges of the pallet.

Another object of the present invention is to provide an apparatus for assembling layers of packages on a pallet at the rate of at least about twenty packages per minute, with each package in each layer having a predetermined orientation and with the packages in each layer arranged in a predetermined pattern.

Still another object of the present invention is to provide an apparatus for assembling bags, each having a sewn end and a butt end, in layers on a pallet with the bags in each layer having a predetemiined orientation and with the sewn end of bag in each layer facing inwardly of thelayer. I

The method of the present invention achieves many of the above objects with the steps of: conveying packages in a first direction with each package oriented in a given direction; conveying the packages in a second direction to a marshalling station; turning selected packages while conveying the same in the second direction; sequentially gathering groups of the packages at said marshalling station; moving the first group of packages gathered at the marshalling station onto a plate while it is in a first position; moving the second group of packages gathered at the marshalling station onto the plate while it is in the first position to form a layer of packages arranged in a predetermined pattern; moving the plate with the layer thereon to a second position over a pallet; and wiping the layer off of the plate while retracting the plate to the first position to deposit the layer on the pallet. The above steps can be repeated a number of times to deposit a number of layers on the pallet with the packages in each layer arranged in a predetermined pattern which facilitates interlocking of each layer with an adjacent layer.

The method of the present invention achieves other of the above objects with the step of turning selected packages substantially 280 while conveying the packages in the first direction.

The apparatus of the present invention achieves still other of theabove objects with an automatic palletizer including: a first conveying mechanism for receiving packages with each package oriented in a given direction and for sequentially conveying the packages in a first direction; a second conveying mechanism for receiving packages from the first conveying mechanism and for conveying the same in a second direction; a turning mechanism operatively associated with the second conveying mechanism for turning selected packages while they are being conveyed on the second conveying mechanism; thesecond mechanism including a marshalling station located downstream from the turning mechanism for receiving and grouping the packages; a layer forming and shuttling station located adjacent the marshalling station and including a shuttle plate; a pusher device for sequentially moving each group of packages from the marshalling station onto the shuttle plate and thereby arrange the packages on the shuttle plate in a layer with the packages in the layer arranged in a predetermined pattern; a pallet elevator mounted adjacent the layer forming and shuttling station and including a mechanism for raising a pallet in the elevator to a predetermined height for receiving a first layer of packages; the layer forming and shuttling station including a mechanism for moving layer forming and shuttling station; the pallet elevator including a mechanism for lowering the pallet in the pallet elevator a predetermined distance after a layer has been deposited on the pallet; and a mechanism for moving a loaded pallet from the pallet elevator after a predetermined number of layers have been deposited on the pallet elevator and for simultaneously moving an empty pallet to the pallet elevator.

The exact manner in which the present invention achieves the above objects, and other objects and advantages inherent inv the invention will become more apparent from the following detailed description of a preferred embodiment of the invention taken in conjunction with the accompanying drawings wherein:

FIG. 1 is a perspective view of the automatic palletizer of the present invention combined with a bag filling and closing machine and a shrink wrap mechanism for wrapping a plastic material around a loaded pallet;

FIG. 2 is a side elevational view, with portions removed, taken along line 2-2 of FIG.,1, and showing a 180 turning mechanism located in a first feeding zone of the palletizer;

FIG. 3 is a top plan view, with portions broken away, taken along line 3--3 of FIG. 2;

FIG. 4 is a side elevational view taken along line 44 of FIG. 1, and showing .a turning mechanism located in a second feeding zone of the palletizer;

FIG. 5 is a top plan view, with portions broken away, taken along line 55 of FIG. 4;

FIG. 6 is a view similar to the view shown in FIG. 5, and showing the 90 turning mechanismoperated to begin turning a bag 90 FIG. 7A, 7B and 7C are fragmentary top plan views similar to the view shown in FIG. 6, and showing sequential positions of abag as it is being turned 90 by the 90 turning mechanism; I

FIG. 8 is a fragmentary top plan view taken along line 88 of FIG. 1 and showing a holding area in the second feeding zone for holding three bags;

FIG. 9 is a top plan view, with portions broken away, taken along line 99 of FIG. 1 and showing a marshalling station at the downstream end of the second feeding zone, a layer forming and shuttling station located adjacent the marshalling station, and a group of bags being moved by a pusher device onto a shuttle plate in the layer forming and shuttling station;

FIG. 10 is a top plan view of the layer being formed in FIG. 9;

FIG. 11 is a side elevational view, with portions broken away, taken along line 11-11 of FIG. 1 and showing the layer forming and shuttling station, a pallet elevator, a pallet dispenser, and a pallet conveyor, of the palletizer;

FIG. 12 .is a top plan view, with portions broken away, taken along line 12-12 of FIG. 11, showing a layer having another predetermined pattern, which is in opposite hand relation to the pattern shown in FIG. 10,

as it is being wiped off the shuttle plate to deposit the layer over a pallet in the pallet elevator, and showing spreading mechanisms for spreading apart the two bags arranged end to end in the layer;

FIG. 13 is atop plan view of a layer, having the pattern shown in FIG. 12, after it has been deposited on the pallet in the pallet elevator and the two bags extending end to end in the layer have been separated to square up the corners of these two bags with the outer corners of the outer two bags of the other bags arranged side by side in the layer;

FIG. 14 is a sectional view, with portions broken away, taken along line 14-14 of FIG. 12, and showing the lift mechanism for lifting and supporting a pallet in the pallet elevator;

FIG. 15 is an enlarged perspective view of one lift member of the lift mechanism shown in FIG. 14;

FIG. 16 is a sectional view, with portions broken away, taken along line 16-16 of FIG. 11, and showing one of the star wheel feeding members of the pallet dispenser for depositing pallets sequentially and individually on the pallet conveyor;

FIG. 17 is a schematic diagram of the electrical circuit for controlling operation of the 180 turning mechanism shown in FIGS. 1, 2 and 3;

FIG. 18 is a schematic diagram of the electrical circuit for controlling operation of the 90 turning mechanism shown in FIGS. 1 and 4-7C; and

FIGS. 19A and 19B, taken together, show a schematic diagram of the electrical circuits for controlling operation of the pusher device shown in FIGS. 1 and 9, the shuttle plate shown in FIGS. 1, 9 and 11, the pallet elevator shown in FIGS. 1 and 11, the spreading devices shown in FIGS. 1, l1 and 12, the pallet dispenser shown in FIGS. 1, 11 and 16, the pallet conveyors shown in FIGS. 1 and 11.

Referring-now to the drawings in greater detail, a bag handling system 2 is shown in FIG. 1 and includes a bag filling and closing machine, generally indicated at 4, the automatic palletizer of the present invention, generally indicated at 6, and a shrink wrap mechanism generally indicated in phantom lines at 8. The system 2 fills and seals bags, arranges the bags on a pallet in eight layers with each layer having a predetermined pattern, and then shrink wraps a plastic material around the loaded pallet to provide a stable wrapped pallet with eight layers of bags. In the illustrated embodiment, each layer is formed with one of two interlocking patterns, Aor B, which are in opposite hand relation to each other; and adjacent layers have alternate patterns. The two patterns A and B are best shown in FIGS. and 13, respectively, and will be described in detail in connection with the description of FIGS. 10 and 13.

The bag filling and closing machine 4 and the shrink wrap mechanism 8 are of known construction. The automatic palletizer 6 can be used by itself, or in combination with the machine 4 and/or the shrink wrap mechanism 8.

The bag filling and closing machine 4 includes a continuous conveyor 10 for carrying bags 12 in a generally upright position. In this respect, a closed bottom or butt end 14 of each bag 12 is supported on the conveyor 10. Although not shown, it will be understood that the upper end 16 of each bag is initially open for receiving material which is dispensed into the bag by a filling mechanism generally indicated at 18. Downstream from the filling mechanism 18 is a closing or sealing mechanism, generally indicated at 20, where the upper end 16 of each bag 12 is closed after the bag 12 is filled, typically by sewing the upper end 16 of the bag 12. Thereafter, the bag 12 is carried further downstream by the conveyor 10 to a position where a kicker 22 is located. When the bag 12 is opposite the kicker 22, the kicker 22 is operated to kick the bag 12, sewn end first, into a first feeding zone 24 of the palletizer 6.

The general construction of the palletizer 6 will now be described with reference to FIG. 1.

As shown, the first feeding Zone 24 of the palletizer 6, wherein the bags 12 are fed in a first direction indicated by the arrow 25, includes a first conveyor 26, a 180 turning mechanism 28 associated with the first conveyor 26 for turning selected bags 12, 180 and a second inclined, high speed conveyor 29 which sequentially delivers the bags 12 to a second feeding zone 30.

The second feeding zone 30, inwhich the bags 12 are fed in a second feeding direction, indicated by the arrow 31, to the first direction, includes a live bottom roller conveyor 32, a 90 turning mechanism 34 at the upstream end 35 of the conveyor 32 for turning selected bags 12, 90 and a bag holding area 36 which is separated by a vertically reciprocal gate 37 from a marshalling station 38 located within the second feeding zone 30 at the downstream end 39 of the conveyor 32. A pusher device 40 is normally positioned on one side 41 of the conveyor 32 and in position to push bags gathered in a group at the marshalling station 38 off of the conveyor 32 into a layer forming and shuttling station 42 which is located adjacent the other side 43 of the conveyor 32 and which includes a shuttle plate 44 on which first and second (and third and fourth) groups of bags 12 are arranged to form a layer of bags 12 having a pattern A (a pattern B) as shown in FIG. 10 (FIG. 13).

A pallet elevator 46 is located adjacent one side of the layer forming and shuttling station 32, and the shuttle plate 44 is arranged for movement from a first position in the layer forming and shuttling station 42 to a second position within the pallet elevator 46 for depositing a layer of bags 12 from the shuttle plate 44 onto a pallet 47 in the pallet elevator 46.

A pallet supply station 48 including a pallet dispenser 49 is located adjacent the pallet elevator 46 opposite the layer forming and shuttling station 42. A pallet conveyor 50 extends through the pallet supply station 48 and the pallet elevator 46, and through the layer forming and shuttling station 42 beneath the shuttle plate 44. In this illustrated embodiment, four layers 51 are shown deposited on the pallet 47 in the pallet elevator 46.

As shown in FIG. 1, another conveyor 52 is situated at the downstream end 53 of the conveyor 50. It will be understood that the loaded pallets are moved from the conveyor 50 onto the conveyor 52 during the operation of the palletizer 6. In the illustrated embodiment, the conveyor 52 is a powered conveyor and defines a pick up station 54 for receiving and holding loaded pallets (not shown) received from the conveyor 50 until they are picked up by forklift trucks (not shown) which are used to move the loaded pallets to a storage area (not shown). To prevent a fork lift truck from engaging and damaging the conveyor 52, a guard rail 56 is along the outer side 57 of the conveyor 52.

In anotherembodiment of the invention, the conveyor 52 is also powered and forms part of a conveyor mechanism, indicated by phantom lines at 58, of the shrink wrap mechanism 8. In this other embodiment of the invention, the pick up station will be located downstream of the conveyor mechanism 58 as indicated generally at 59.

The general operation of the system 2 will'now be described with reference to FIGS. 1, 10 and 13.

As describedabove, the bags 12 are sequentially filled and closed by the filling and closing machine 4. When each bag 12 reaches the position adjacent the kicker 22, the kicker 22 is operated to push each bag 12, sewn end first, onto the conveyor 26 in the first feeding zone 24 with each bag 12 aligned on the conveyor 26 with its longitudinal axis extending generally parallel to the first feeding direction indicated by the arrow 25. Then, selected bags 12 received on the conveyor 26 are turned 180 by the turning mechanism 28.

positioned The conveyor 26 then delivers each bag 12 to the high speed inclined conveyor 29 which throws each bag 12 onto the upstream end 35 of the conveyor 32 in the second feeding zone 30 with each bag 12 initially positioned on the conveyor 32 with its longitudinal axis extending transversely of the second feeding direction indicated by the arrow 31. Then, selected bags 12 are quickly turned 90 by the 90 turning mechanism 34. After passing, or being turned by, the 90 turning mechanism34, the bags 12 are carried by the conveyor 32 to, the marshalling station 38 with eachbag 12 having a predetermined orientation.

As a result of being turned once, twice or not at all, each bag 12 will have one of four predetermined orientations which is at least 90 different from the other orientations. In this respect, the four orientations are analogous to the X, Y, .-X and Y axes in a cartesian coordinate system. Each bag 12 is given one of these predetermined orientations in order to form one of two layer patterns A or B (FIGS. 10and 13) on the shuttle plate 44. In this respect, layers with alternate patterns A, B, A, B, etc. are sequentially formed on the shuttle plate 44 and then sequentially deposited on the pallet 47 in the pallet elevator 46. I

Referring to FIG. 10, the first layer pattern A is formed with four bags 12 a-d arranged side by side with the butt ends 14 thereof facing along one side of the layer 51, so that the sewn ends 16 12 inwardly of the layer, and with two bags 12e and 12 f arranged end to end with the sewn ends 16 abutting each other (that is to say, with the sewn ends 16 facing inwardly of the layer). The layer pattern B is formed in a similar manner, but in opposite hand relation to the layer pattern A, with two bags 12 g and 12 12 arranged end to end and four bags 12 i-l arranged side by side as shown in FIG. 13.

Each of the mechanisms 28 and 34 is an electrically controlled-pneumatically powered mechanism. To obtain the proper orientation of each bag 12 as it is fed through the first and second feeding zones 24 and 30, each zone is provided with an individual control circuit including at least one bag sensing device for controlling the'operation of the respective turning mechanisms 28 and 34 independently of each other. In this respect, a

' 8 bag sensing device 60 (FIGS. 1, 2 and 17) is associated with the 180 turning mechanism and bag sensing devices 60 (shown schematically in FIG. 18) and 61 (FIGS. 5 and 18) are associated with the 90 turning device 34. In the illustrated embodiment, the sensing devices 60, 60' and 61 are limit switches. As will be described in greater detail in connection with the description of the schematic diagram in FIG. 17 (18), the control circuit for the turning mechanism 28 (34) includes a 12 position stepping switch or cam 60 b (61 26..Afterwards, the sensing devices 60 and 60' sense the turned bag 12a, the sensing device 60 causing advancement of the cam 60. b'to its second position and the sensing device 60 causing advancement of the'cam 61 c in the control circuit for the second feeding zone 30. In the second feeding zone 30, the bags 12 will contact the sensing device 61. As will be more fully explained in connection with the description of FIG. 18, the turning mechanism 34 is operated for the fifth, sixth, seventh and eighth bags 12 e-h. Such operation ofthe 90 turning mechanism 34 is initiated upon the sensing of one of these bags 12 e-h by the sensing device 60 and is completed upon the sensing of that bag by the sensing device 61, to cause turning of that bag 90.

Using the analogy of the cartesian coordinate system, and with the longitudinal axis of an unturned bag constituting the +X axis, the bag 12 a given an orientation which places its longitudinal axis on the X axis and the bag 12 e is given an orientation which places its longitudinal axis on the Y axis. It will be understood, that in the like manner, the other bags 12 b-d and. 12 f-l are each given a predetermined orientation. The turning operation for each bag 12 for each position of each cam 60b and 61c as well as the orientation given each bag are set forth in Table I below.

TABLEI Carn Po- 90 si- Turning Turning Orien- Layer Bag tion Mechanismmechanism tation Group Pattern 12a 1st Operated -X 12b 2nd Operated X' 1 12: 3rd Operated X A 12d 4th Operated X 122 5th Operated Operated -Y} 2 12f 6th Operated v 12g 7th Operated Operated Y} 3 12!: 8th Operated +Y 121' 9th +X B l2j 10th +X 1 4 12k llth +X 121 12th After each bag 12 is given a predetermined orientation it is carried downstream to the marshalling station 38 which sequentially gathers four predetermined groups of bags 12 which each group having a predetermined array. As indicated in Table I, the first group comprises four bags 12 a-dwhich are gathered in'the marshalling station 38 arranged side by side with the butt ends 14 thereof facing toward the shuttle plate 44. After this first group of bags 12 a-d is moved onto the shuttle plate 44 by the pusher device 40, a second group comprising two bags 12 e and 12 f are gathered in the marshalling station 38 arranged end to end with the sewn ends 16 thereof abutting each other. Then, this second group is moved by thepusher device 40 onto the shuttle plate 44 to form a layer of bags 12 hav ing the pattern A shown in FIG. 10.

The next layer, having a pattern B, will then be formed with a third group of two bags 12 g and-12 h arranged end to end with the sewn ends abutting each other in the same manner-as the second group, and a fourth group of four bags 12 i--l arranged side by side, but in opposite hand relation to the first group.

While the first six bags 12 a-f are being orientated, grouped and then formed into a layer having a predetermined pattern, the pallet 47 is being moved by the conveyor 50 from beneath the pallet dispenser 49 of the pallet elevator 46 and then raised in the pallet elevator 46 to a predetermined height just below the height of the shuttle plate 44. After the pallet 47 has reached the predetermined height and a layer has been formed on the shuttle plate 44, the shuttle plate 44 is moved from its first position, in a direction parallel to the second feeding direction indicated by the arrow 31, into the pallet elevator 46 to its second position over the pallet 47 in the pallet elevator 46. A pivoted gate 62, positioned between the pallet elevator 46 and the layer forming and shuttling station 42, is then swung down from a horizontal position to a vertical position where the lower edge of the gate 62 extends in a horizontal plane slightly above the shuttle plate 44. The shuttle plate 44 is then retracted to its first position in the layer forming and shuttling station 42. When this is done, the gate 62engages one side of the layer 51 on the shuttle plate 44 and sweeps or wipes the layer 51 off of the shuttle plate 44 to deposit the layer 51 on the pallet 47 in the pallet elevator 46. The pallet 47 with one layer 51 thereon is then lowered a predetermined distance in the pallet elevator 46 to a position for receiving the next layer assembled on the shuttle plate 44.

After the pallet 47 in the pallet elevator 46 has been loaded with a predetermined number of layers, eight layers in the illustrated embodiment, the pallet 47 will have been lowered onto the conveyor 50 and the conveyor 50 is actuated to move the loaded pallet either onto the conveyor 52 at the pallet pick up station 54, or onto the conveyor mechanism 58 of the shrink wrap mechanism 8 for shrink wrapping a plastic material around the loaded pallet, after which the wrapped loaded pallet is moved to the pick up station 59.

At the same time the loaded pallet is moved to the pick up station 54 or 59, an empty pallet 63 (FIG. 16) which had been resting on the conveyor 50 beneath the stack 64 (FIG. 16) of pallets at the pallet supply station 48 is moved to the pallet elevator 46 and then raised therein to the predetermined height below the height of the shuttle plate 44.

The manner in which the above described operations are effected will be more fully explained in connection with the description of FIGS. 19A and B.

Referring now to FIGS. 2 and 3, it will be noted that the conveyor 26 is supported on a framework 65 (FIG.

, 2) which also supports two deflecting baffles 66 and 67 (FIG. 3). The baffles 66 and 67 align each bag 12 on the center line of the conveyor 26 as the bag 12 is kicked from the conveyor 10 onto the conveyor 26. They also guide each bag 12 into the 180 turning mechanism 28. The guiding of a bag 12, as it is kicked onto the conveyor 26, is generally indicated by phantom lines at 12 x in FIG. 2. I

As best shown in FIG. 3, the 180 turning mechanism 28 includes an inverted U-shaped frame member 68 having a bight portion 69, which extends acrossv and straddles the conveyor 26, and two legs, 70 and 71 which are secured to the framework 65. A journal box 72 (FIG. 2) is mounted to the bight portion 69 midway between the legs 70, 71 and rotatably supports a shaft hidden from view. The lower end of this shaft is connected to a guideway, generally indicated at 73, which includes an inverted U-shaped frame member 74 having depending legs 75 and 76 and guide panels 77 and 78 secured respectively to the depending legs 75 and 76 on opposite sides of the longitudinal center line of the conveyor 26. It will be understood that the axis 79 of the shaft (not shown) is generally perpendicular to the longitudinal center line of the conveyor 26 which may be inclined slightly, as shown in FIG. 2, or may be level with an intermediate drive, such as a roller, interposed between the conveyors 26 and 29. Preferably, a cross bar 80, 81 is rigidly fixed to the lower end of each leg 75, 76 to .provide lateral support for each guide panel 77, 78.

A sprocket 82 is secured to the upper end of the shaft and is driven by a chain 83 which, in turn, is driven by a pair of opposite, double acting piston and cylinder drive mechanisms 86 and 87. The drive mechanisms 86 and 87 are supported by a framework 89 secured to and extending from the bight portion 69 of the frame member 68 in cantilever fashion. Preferably, to provide a more rigid structure, the baffles 66, 67 are secured to the bight portion 69 of the frame member 68 by brackets 90 (FIG. 3).

Each drive mechanism 86, 87 is pneumatically operated and electrically controlled and includes a piston rod 91, 92. The outer end of each rod 91, 92 is secured to one end of the chain 83 as best shown in FIG. 3. It will be understood that when the drive mechanisms 86, 87 are actuated, the piston rods 91 and 92 will be moved in opposite directions to move the chain 83 in one direction with push-pull forces applied thereto, to turn the sprocket 82 and thereby turn the guideway 73 about the axis 79 of the shaft (not shown) to turn a bag 12, received between the panels 77 78 of the guideway 73,

To stop forward movement of a bag 12 as it travels on the conveyor 26 in the first feeding direction indicated by the arrow 25, the 180 turning mechanism 28 includes a movable stop 94 which is movable to and from a position over the conveyor 26 in the path of movement of the bags 12. As shown, the stop 94 includes a pair of plates 95 and 96 pivotally connected to each other and biased apart by a helical torsion spring as indicated at 97. The plate 96 is fixed to a depending mounting bracket 98 which is mounted for pivotal movement about a pivot axis 99. Fixed to the lower end of the plate 96 is a limit switch 100 which is closed when the leading end of a bag 12 traveling on the conveyor 26 engages the plate 95 of the stop 94 and pushes the plate 95 againstthe plate 96. As shown in FIG. 2, two piston and cylinder drive mechanisms 101 and 102 are connected to the framework 89 and'to the bracket 98 for pivoting the stop 94 about the pivot axis 99. The bag sensing device 60 is also mounted to the framework 89 and depends therefrom into the path of the bags 12 on the conveyor 26.

Depending upon the position of the cam 60 f the stop 94 is in or out of position for stopping movement of a bag 12 traveling on the conveyor 26. When the stop 94 is in position to stop a bag 12, engagement of the stop 94 by a bag 12 will cause closing of the limit switch 100 to cause operation of the drive mechanisms 86 and 87 to rotate the guideway 73 about the vertical axis 79 to turn the bag 180 A bag being turned 180 is indicated by phantom lines at 12 y in FIG. 3.After the selected bag 12 is rotated 180, the drive mechanisms 101 and 102 are operated to return the stop 94 to its raised position out of the path of travel of the bags 12 on the conveyor 26. From FIGS. 2 and 3, it is apparent that one selected bag 12 will be rotated in a counterclockwise direction 180 and then the next selected bag will be rotated in a clockwise direction'180. In other words, the chain 83 is reciprocated upon each two turnings of selected bags 12 and the drive mechanisms 86 and 87 provide a simple, compact and efficient means for reciprocating the chain 83 to turn selected bags 12 180.

Referring now to FIG. 17, it will be understood that the electrical control circuit for operating the 180 turning device 28 is supplied from a conventional 110 volt a.c. source through a main disconnect switch indicated atS via lines L and L As shown, line L; is grounded and line L, is connected to one lead 60 a leading to a 12 position stepping switch or stepping cam 60 b and to one side of the limit switch 60. When the stepping cam 60 b is in position 1 as shown, a closed circuit is established across the cam 60 11 between the lead 60 a and a lead 60 c which is connected to contacts 1-5 and 7 on the stepping cam 60 b. The lead 60 c is also connected to one side of the limit switch 100 and to one side of a solenoid 60 d. The outer side of the solenoid 60 d is connected to a normally closed switch- S so that when the stepping cam is in the first position, the solenoid 60 d is normally energized to move an armature associated with a valve V to a .position for actuating the drive mechanisms 101 and 102 to lower the stop 94 for engaging the first bag 12 a traveling on the conveyor 26.

timer T, will cause opening of the switch S to de-energize timer T The timer T is of the vacuum type which times for a period of a few seconds after being deenergized, typically 3-4 seconds (a sufficient time for the bag 12 a to be turned 180 and then carried by the conveyor 26 past the limit switch 60), after which the timer T causes closing of the switch S Each time a bag 12 engages and closes the limit switch 60, a solenoid 60 e is energized to actuate an advancing armature 60 f for moving the stepping switch 60 b one position. Thus, engagement of the limit switch 60 by the bag .12 a will cause the cam 60 b to be moved to the second position and a circuit will again be completed between lead 60 a and lead 60 c so that after 'three to four seconds elapse (during which time the bag 12 a is turned 180 and passed through the turning device 28 and the stepping cam 60 b is advanced to the second position). the switch S will be closed again to energize the solenoid 60 d to lower the gate into position to engage the next bag 12 b traveling on the conv'eyor 26. v I

The closing of the limit switch 100 will also energize one side of a limit switch LS, which will be in one of two positions. In the first position it is connected to relay coil OC which, when energized will open relay contacts v60 g. In the second position it is connected to arelay coil CC which, when energized, will close relay contacts 60 g. The contacts 60 g are connected between line L and a solenoid 60 h which operates an armature associated with a valve V for controlling the flow of compressed air to the piston and cylinder drive mechanisms 86 and 87. The limit switch LS is moved to one or the other of its first and second positions by a cam 60 i which is mounted on the -1 turning mechanism 28.

As shown in FIG. 17, the limit switch LS had been moved from position 2 to position 1 during the last operation of the 180 turning mechanism 28, so that, when-bag 12 a engages and closes limit switch 100, relay coil 0C is energized to open contacts 60 g to deenergize solenoid 60 h. This will actuate the valve V to operate the piston and cylinder drive mechanisms 86 and 87 to retract piston rod 91 and extend piston rod 92 -to turn guideway 73, with bag 12 a therein, 180.

It will be appreciated, of course, that when the bag 12 a is turned, the limit switch is open so that neither the coil OC nor the coil CC will be energized as the cam 60 i on the 180 turning mechanism engages and moves the limit switch LS from position 1 to position 2, and, when the limit switch 100 is closed again, the relay coil CC is energized to cause the piston rod 92 to be retracted and the piston rod 91 to be extended to cause the guideway 73 to be turned 180 in the opposite direction to turn the next bag 12 b 180.

When the cam 60 b is moved to position 6 or 9, no circuit will be completed through cam 60 b between lead 60 a and 60 c so that, when the timer T times out and switches S is closed, the solenoid 60 d will not be energized to lower stop 94.

As shown in FIGS. 1 and 4, the first feeding zone 24 also includes the high speed inclined conveyor 29 which receives bags 12 from the conveyor 26 and literally throws the bags 12 onto the upstream end 35 of the conveyor 32 in the second feeding zone 30. In one embodiment of the invention a marker is positioned above the high speed inclined conveyor 29 for marking each bag 12 with a desired marking or number. Of course, the marker 105 may be eliminated or placed elsewhere along the path of travel of thebags 12. If desired, the limit switch 60 (FIG. 18) can be mounted over the conveyor 29.

As shown in FIGS. 4 and 5, the conveyor 32 includes a plurality of rollers 107 which are supported by a framework 108 and are driven by a continuous belt 109. After each bag 12 (such as the bag 12 a) is thrown onto the upstream end 35 of the conveyor 32, the longitudinal axis of the bag 12 will initially extend transversely of the conveyor 32 and the bag 12 will contact the bag sensing device 61 which extends upwardly between two of the rollers 107.

The 90 turning mechanism 34 includes a deflector member 112 which is positioned for movement from the one side 41 of the conveyor 32 into the path of movement of one portion of each of the bags .12 received on the conveyor 32. As shown, a piston and cylinde'r mechanism 114 is connected to the deflector member 112 for moving the same. The turning mechanism 34 also includes a movable guide member 116 which, when not operated, is positioned at the upstream end 35 of the conveyor 32 near the other side 43 of the conveyor 32 and out of the path of the bags 12, as shown in FIGS. 4 and 5. The guide member 116 is in the form of a cylinder or roller and, as best shown in FIG. 4, is secured to a vertical mounting bar 118 which is suspended from a bracket 119 mounted for horizontal sliding movement on a guide bar 120. The guide bar 120 is supported above the conveyor 32 by a framework 121 mounted to the framework 108. A cylinder 122 (fully shown in FIG. 1) is mounted to the framework 121 above the guide rod 120 and a double acting piston (not shown) is positioned within the cylinder 122. A tape 123 is connected to the piston and the ends of the tape 123 are secured to the bracket 119 as indicated at 124, 125 in FIGS. 5 and 6. It will be understood that when fluid is admitted to one end of the cylinder 122, the piston is actuated to move the tape 123 to move the guide member 116 either in a forward direction parallel to the second feeding direction indicated by the arrow 31, or in a reverse direction 180 to the second bag feeding direction. Preferably, a guide bar 126 (FIGS. 1 and 4) is mounted to the framework 121 at the upstream end 35 adjacent the side 43 of the conveyor 32, and is positioned to engage and laterally support and guide the vertical mounting bar 118 when the guide member 1 16 is moved.

In FIG. 5, the guide roller 116 and the deflector member 1 12 are in their retracted positions and the bag 12 a is shown being fed downstream on the conveyor 32 in the second bag feeding direction indicated by the arrow 31 without having been turned by the 90 turning mechanism 34.

After a predetermined number of bags have contacted the bag sensing device 60', the cam 61 c for the second feeding zone 30 is advanced to a position where a circuit is closed to actuate the piston and cylinder mechanism 114 to cause the deflector member 112 to be projected from the one side 41 of the conveyor 32' closed to actuate the cylinder 122 for moving the guide roller 116 in the forward direction indicated by the arrow 31.

As shown, the bag 12 e has already been turned 180 by the bag 180 turning mechanism 28 such that the leading end of the bag 12 e (hereinafter referred to as the first end 127a) as it is thrown onto the conveyor 32 is the butt end 14 of the bag 12 e and the trailing end (hereinafter referred to as the second end 127 b) is the sewn end 16 of the bag 12 e. The first or leading side of the bag 12 e as it starts to move on the conveyor 32 is indicated at 127 c and the second or trailing side is indicated at 127 d. The turning of the bag 12 e will now be described with reference to FIG. 6 and FIGS. 7A-7C.

As shown in FIG. 6, when operation of the 90 turning mechanism 34 is initiated upon sensing of the bag 12 e by the sensing device 60, the deflector member 112 is moved over .the conveyor 32 in position to engage the first side 127 c of the bag 12 e near the second end 127 b of'the bag 12 e, and then, when the bag 12 e engages the bag sensing device 61, the reciprocal guide member 116 is moved into engagement with the second side 127 d of the bag 12 enear the first end 127 a. Thereafter, as shown in FIG. 7A, the guide member 116 is moved in a forward direction along the second side 127 d of the bag 12 e and toward the first end 127 a of the bag 12 e with the deflector member 112 maintained in its blocking position. In this way, and as shown in FIGS. 7A and 7B, the guide member 116 cooperates with the deflector member 112 in turning the bag 12 e as the guide member 116 is moved forward. Moreover, the deflector member 112 has a curved or rounded deflecting surface to facilitate the turning of the bag 12 e about the deflector member 112.

When the guide member 116 moves in the forward direction, to quickly turn the bag 12 e about the deflector member 112, it can impart sufficient momentum to the bag 12 e to turn the bag 12 e more than 90 such that the longitudinal axis 128 of the bag 12 e is inclined at a slight angle to the feeding direction indicated by the arrow 31, as best shown in FIG. 7B. To correct this slight misalignment, that is to say, to align the bag 12e with its longitudinal axis 128 parallelto the feeding direction indicated by the arrow 31, the guide member 116 is moved in the second or reverse direction, after the bag 12 e passes over or clears the sensing device 61, to again engage the second side 127 d of the bag 12 e, and then is moved along the second side 127 d toward the second end 127 b while the deflector member 112 is maintained stationary as shown in FIG. 7C. In this way, the guide member 116 and the deflec tor member 112 cooperate in aligning the bag 12 e with its longitudinal axis 128 parallel to the feeding direction indicated by the arrow 31, as the guide member 116 ismoved in the reverse direction to its starting position. It will be understood, that while the guide member 116 is moving back and forth, the rollers 107 are urging the bag 12 being turned in the second feeding direction indicated by the arrow 31. After a bag 12 is turned 90, it is carried downstream through the bag holding area 36.

The electrical control circuit for the 90 turning mechanism 34 is shown in FIG. 18 and includes a limit switch 60' which can bepositioned next to the limit switch 60 (as indicated schematically in FIGS. 17 and 18) or over the high speed inclined conveyor 29. Closing of the limit switch 60 will cause energization of a solenoid 61 a which is connected in series with limit switch 60 between lines L and L for moving an armature 61 b to advance a 12 position stepping switch or cam 61 c one position. When the fifth bag 12 e engages and closes the limit switches 60 and 60, the armature 61 b is moved to advance the stepping cam 61 c to its th position. A circuit will then be closed between a lead 61 d connected to line L and a lead 61 e connected to the fifth through eighth contacts on the stepping cam 61 c. When this circuit is completed across cam 61 c between lead 61 d and 61 e, a solenoid 61 f is energized to operate a valve V to cause the drive mechanism 114 to move the deflector member 112 over the live bottom roller conveyor 32. Then, when the fifth bag 12 e is thrown onto the conveyor 32 and engages v and closes the limit switch 61, another solenoid 61 g is energized to operate a fourth valve V; which controls the flow of compressed air to the cylinder 122. In this respect, when the limit switch 61 is closed and the solenoid 61 g is energized, the valve V. is operated to apply compressed air to thecylinder 122 to cause the guide member 116 to be moved in a forward direction. Then, after the bag 12 e is turned and the trailing end of the bag 12 e has passed over the limit switch 61 releasing the same, the solenoid 61 g is deenergized and the valve V is operated to apply compressed air to the cylinder 122 to cause the guide member 116 to be moved in the reverse direction, to retract the same to its at-rest position at the upstream end 35 of the conveyor 32, and in so doing, cooperate with the deflector member 112 in aligning the bag 12 e with its longitudinal axis 128 extending parallel to the second feeding direction 31. Upon each succeeding advancement of the stepping Cam 61 c to the sixth, seventh and eighth positions, respectively, a circuit will again be established between leads 61 d and 61 e for causing the deflector member 112 to be extended and for enabling the limitswitch to cause operation of the guide member 116 when the limit switch 61 is closed by each of the bags 12f, 12 g and 12 hfor turning each of these bags 90 in the manner described above.

The construction and general operation of the remaining mechanisms of the palletizer 6 will now be described, followed by the description of the manner in which these mechanisms are operated, in conjunction with the description of the control circuits therefor shown in FIGS. 19A and 19B.

Since the filling of the bags 12 by the bag filling and closing mechanism 4 is continuous, the bags 12 are fed continuously through the first feeding zone 24 to the second feeding zone 30 and then toward the marshalling station 38 at the downstream end 39 of the conveyor 32 in the second feeding zone 30. However, the pushing of each group of bags 12 from the marshalling station 38 onto the shuttle plate 44 and the shuttling of a layer of bags 12 from the layer forming and shuttling station 42 onto a pallet 47 in the pallet elevator 46 is intermittent, and will be delayed when a loaded pallet is moved from the pallet elevator 46 and the unloaded pallet 63 is moved into the pallet elevator 46 and raised to the predetermined position just below the height of the shuttle plate 44. When this delay occurs, it is desirable to prevent bunching up of the bags 12 at the marshalling station 38. For this purpose the second feeding zone 30 includes the holding area 36.

The holding area 36 includes several stop means, the first stop means being the gate 37, which is lowered after a group of bags 12. has been gathered in the marshalling station 38, to stop the next bag 12 (such as the bag 12 i) traveling along the conveyor 32, as shown in FIG. 8. When this occurs, the bag 12 i will close a switch, indicated by phantom lines at 130, which extends upwardly between two of the rollers 107. The closing of the, switch energizes a solenoid (indicated schematically at 288 in FIG. 19A) for projecting two buttons 131 and 132 upwardly between another two of the rollers 107 on opposite sides of the belt 109 and into the path of the bags. 12 on the conveyor 32 to form a second stop means for stopping the next bag 12jasshown. f

In like manner, when the loaded pallet 47 is being removed from, and an empty pallet 63 is beingrnoved into, the pallet elevator 46, and forward movement of the pusher device 40 to cause opening of. the gate 37 is prevented, the bag 12 j will close a switch, indicated by phantom lines at 133, which energizes a solenoid (indicated schematically at 289 in FIG. 19A) to project buttons 134,135 upwardly between another two of the rollers 107 to form a third stop means for stopping the next bag 12 k. Again, in like manner, the bag 12k will close a switch, indicated by phantom lines at 136, which controls the operation of a gate 137 to cause'the gate 137 to be lowered to stop movement of the next bag 121.

In this way, bunching up of the bags '12 i-l while pallets are being changed is prevented and the bags 12 i-k are held at spaced apart locations in the holding area 36. It should be notedthat a bag sensing device, which is indicated by phantom lines at 138 and which is shown as a limit switch in FIG. 19A, senses each bag 12 as it travels into the marshalling station 38 and, after a predetermined group of two or four bags 12 have been sensed, a circuit is energized to cause closing of the gate 37. If the bags were allowed to bunch up at the gate- 37, the bag sensing device 138 might not be released until all the bags 12 have traveled past the sensing device 138 and the. sensing device 138 would, in essence, sense only one bag. For this reason also, the buttons 131, 132 and 134, 135, hold the bags 12 i-k spaced apart in the holding area 36. Then, when the gate 37 is opened (raised), causing the buttons 131, 132, 134 and 135 to retract below the rollers 107 and the gate 137 to rise, each bag 12 i-l with be sequentially and individually sensed by the sensing device 138.

In the operation of the palletizer 6 of the present invention with one known type of bag filling and closing mechanism 4, the time in which the bags 12 are filled, closed and then kicked onto the conveyor 26 in the first feeding zone 24 relative to the speed of operation of I the various mechanisms of the palletizer 6, particularly the speed of the pallet elevator 46 and the pallet conveyor 50, in such that, after the exchange of pallets, pusher device 40 is allowed to move forward to energize a circuit to cause opening (raisinglof the gate 37 and retraction of the buttons 131, 132, 134 and 135 just as the switch 136 is closed and the gate 137 starts 

1. Method for assembling at least one layer of packages on a pallet with the packages in each layer arranged in a predetermined pattern, said method comprising the steps of: conveying packages in a first direction with each package oriented in a given direction; conveying said packages in a second direction to a marshalling station; turning selected packages while they are being conveyed in said second direction; sequentially gathering groups of said packages at said marshalling station; moving the first group of packages gathered at said marshalling station onto a plate while it is in a first position; moving a second group of packages gathered at said marshalling station onto said plate while it is in said first position to form a layer of packages arranged in a predetermined pattern; moving said plate with said layer thereon to a second position over a pallet; and wiping said layer off of said plate while retracting said plate to said first position to deposit said layer on said pallet; each layer of packages arranged on said plate including two packages arranged end to end in abutting relationship and a plurality of other packages arranged side by side, the longitudinal extent of said two packages abutting each other end to end being less than the lateral extent of said other packages arranged side by side, said method further including the step of spreading apart said abutting ends of said two packages arranged end to end while wiping said layer off of said plate onto said pallet whereby the outer ends of said packages arranged end to end on said pallet will be in line with the outer facing sides, respectively, of the outer two packages of said other packages arranged side by side on said pallet.
 2. The method of claim 1 wherein each package conveyed in said second direction is initially positioned with one axis thereof extending transversely of said second direction, and each selected package is quickly turned, first, by obstructing movement of one side of a selected package near one end thereof and, second, by moving a guide member in a forward direction substantially parallel to said second direction and into engagement with the other side of said package and then along said other side toward the other end of said package while obstructing said one side near said one end to turn said package.
 3. The method of claim 2 including the step of moving said guide member in a reverse direction into engagement with said other side of said package and then along said other side toward said one end of said package, while engaging said one side at said point where it was obstructed, to align said package with said one axis of said package substantially parallel to said second direction.
 4. A method for quickly assembling packages in at least one layer having a predetermined pattern, said method including the steps of: conveying said packages to a layer forming station with a given axis of each package extending transversely of the direction it is being conveyed at one point in time during the conveying thereof; quickly turning selected packages at said point in time while they are being conveyed, first, by obstructing forward movement of one side of a selected package near one end thereof, and second, by moving a guide member in a forward direction substantially parallel to said conveying direction and into engagement with the other side of said package and then along said other side of said package toward the other end of said package while obstructing said one side of said package near said one end thereof to turn said package; and sequentially forming said packages into a layer having a predetermined pattern at said layer forming station.
 5. The method of claim 4 wherein the step of quickly turning said selected bags includes the further step of moving said guide member in a reverse direction and into engagement with said other side of said package and then along said other side toward said one end of said package, while engaging said one side of said package at said point where it was obstructed, to align said package with said given axis of said package substantially parallel to said conveying direction. 